Flat spring and structure



y 8, 1954 N. T. VOLSK 2,678,685

' FLAT SPRING AND STRUCTURE Filed Feb. 27, 1948 4 Sheets-Sheet 1 Fl G.

IN VEN TOR.

y 13, 1954 NT. VOLSK 2,678,685

FLAT SPRING AND STRUCTURE Filed Feb. 27. 1948 4 Sheets-Sheet 3 FIG. 3A

O 7 INVENTOR.

May 18 1954 N. T. VOLSK 2,678,685

FLAT SPRING AND STRUCTURE Filed Feb. 27, 1948 4 Sheets-Sheet 4 leoe aaoo Ian was IN V EN TOR.

Patented May 18, 1954 UNITED STAT ATENT GFFICE 17 Claims.

This invention relates to fiat springs, methods of making them, and seat structures built of such springs.

The most widely used springs for making seats are spiral or helical springs which possess high efiiciency expressed in allowable energy absorption per pound of metal. The spiral springs also enable one to obtain highly elastic or soft seat cushions and back rests, which possess long natural period of vibration. It is only when. spring structures possess long natural period that it is possible to produce soft, floating ride seats. This excellence of performance and high efficiency are generally obtained at high cost, and by constructing seats which have large cubic displacements. Therefore, if the amount of allowable space for seats is very limited, the use of spiral springs is precluded, and it becomes necessary to resort to the use of some other springs, such as flat or leaf springs, the words flat or leaf signifying that the vertical dimension of the transverse vertical cross-section of such spring is limited, as a rule, only to the thickness of the metal used for making the spring; actually springs of this type are hardly ever flat but represent arcuate, elastic beams supported at two extreme ends. While flat springs enable one to construct seats with smaller cubic displacements and at a lower cost,

these gains are currently obtained at the expense of the desired long period and efficiency, i. e., allowable energy absorption per pound of metal, and the concomitant loss in the elasticity or softness of the entire spring structure. The loss in eiliciency is due to the non-uniform type of stress distribution present in fiat springs, which necessitates increase in the cross-sectional area of these s rings, i. e., increase in their dimensions, and, therefore, weight, until they can support the maximum expected load in spite of this unfavorable stress distribution. This increase in weight lowers the elasticity of the structure and shortens its natural period.

From the above it follows that the performance of flat springs can be enhanced only if they are given a configuration permitting higher allowable energy absorption per pound of metal, which can be obtained only if there is a more uniform type of stress distribution throughout the structure.

The invention discloses a fiat spring structure possessing higher allowable energy absorption per pound of metal and longer natural period than the known flat springs.

It is therefore an object of this invention to provide flat springs possessing higher allowable energy absorption per pound of metal and longer natural period than the known fiat springs.

It is an additional object of this invention to provide flat springs comprising a plurality of interconnected elliptic cells forming an elastic arch, the springs being composed either of independent arches or laterally interconnected arches.

It is also an object of this invention to provide a flat spring composed of two srtaight-edge strips with a. plurality of spaced arcuate columns of elliptic cells between the strips, the cells in each column bein connected to each other and forming an elastic, pro-shaped longitudinal are connected to the edge strip at each end of the are.

It is an additional object of this invention to provide a spring composed of a plurality of longitudinally and laterally integrated elliptic cells, the longitudinal integration connecting a plurality of elliptic cells along their shorter axes to form a longitudinal, arcuate column composed of these cells, and the lateral integration interconnecting the cell columns, all of the columns being connected at each end to an edge strip, and the spring given a permanent arcuate set with the result that the spring, in its entirety, represents an approximately cycloidal, or arouate, elastic sheet with high shearing rigidities and relatively low compressive and flexural rigidities.

Still another object of this invention is to provide seat cushions and back rests utilizing the disclosed types of flat springs.

These and other features of the invention will be more clearly understood from the following detailed description and the accompanying drawings in which:

Figures 1 through 4 are plan views of small portions of integrated elliptic cells forming a spring;

Figure 5 is a perspective view of a single elliptic cell;

Figures 6 and '7 are plan and vertical sectional views respectively of a seat cushion con structed of a spring disclosed in Fig. 2.

Referring to Fig. l, the spring illustrated in this figure comprises two flat, metallic edge strips ID and H and a plurality of rows of longitudinally integrated or interconnected elliptic cells I2. The term elliptic cell, as used'in this specification refers to a substantially ellipticallyshaped spring as clearly illustrated in Fig. 5. This sprin consists of two opposing, bow-shaped leaves 598 and 5H), which will be referred to in this specification as strands, the term used in the expanded metal art, to indicate only approximately similar elements, these strands being connected to each other at their ends to form two rigid, solid metal cell-end junctions 5 l 4, 5H3 between the two strands. These junctions 5 l4, 5H5, are equivalent to, and replace, the usual shackle-and-hanger connections of a conventional elliptic spring. The elliptic cell is connected through solid-metal, central, interstrand connections M8 and 520 to identical strands 522 and 524, respectively, of adjacent elliptic cells, and this pattern of interconnected unitary ellip tic cells repeats itself, as illustrated in Fig. 1, until the interconnected cells form a single column of cells, which column tenninates at each end in an edge strip, such as strips It and il. Qnly two juxtaposed columns of the elliptic cells, symmetrical with respect to the respective longitudinal axes M and [5 of the two columns, are illustrated in Fig. 1. However, in actual practice the number of columns of such elliptic cells is determined by the width of the seat structure,

and it will call for a larger number of columns than two. Each column of the elliptic cells i2 is connected at one end to strip Ill by means of portions [8 of the cells adjacent to the strip. If the longer axis 580 (Fig. 5) of a cell is called the major axis, and the shorter axis 592 is called the minor axis, then it may be stated that the cells are interconnected with each other by means of their central inter-strand connections M8, 520, etc. along their minor axes, thus forming the longitudinal axis 14 or I6 (Fig. 1) and the cells at the ends of each column are connected to the edge strips l6, 5! by means of the strand-edge strip connections I8 where the minor axes of these end cells intersect the edge strips. Therefore, the entire spring represents a plurality of columns of elliptic cells, the cells in each column being metallically connected at their mid-portions, through the interstrand connections 29. to each other along their minor axes to form longitudinal column axes l4 and it, these columns being in turn connected through the strandedge strip connections I8 to two fiat, metallic strips at the point of intersection of the longitudinal axes with the edge strips. The lateral length L of the elliptic cells (Fig. 5), or the length along the major axes 560, is such as to provide gaps 22 (Fig. 1) between the right and left ends of the cells of one column and the corresponding adjacent ends of the cells in adjacent The existence of these gaps, or spaccolumns. ings, between adjacent columns enables the individual cells to elongate laterally, alon their major axes, in two opposite directions, as illustrated by arrows 5M and 586 in Fig. 5, with. strands 598 and 5-H! approaching each other, and the spread 5i 2 of the cell becoming smaller when they are loaded, like in an ordinary elliptic spring under compression, and resume their natural illustrated shape when the load is removed from the spring. The spacing, or gap, 22 between the rolling operation, which transforms the spring into a hollow cylinder having a set due to a heat-treating process or the above rolling operation, and this cylinder is subsequently unrolled against the resistance of the set and fastened to a seat frame. The final shape of the spring is then in a. form of an are or a convex surface, as illustrated in Figs. 6 and '7, and when this are is subjected to loading, it will shorten under load because of the elastic properties of the arc. This shortening of the arc is made possible by constructing the arc itself of a plurality of elliptic cells which can be compressed or expanded, depending upon the load and the resulting are conditions. Under extreme loading the arc may be depressed even below its no-lcad geometric chord 1815, Fig. '7, and when this is the case, the compression of the unit cell is replaced with stretching. In either case there is a complete recovery of the spring to its initial position upon the removal of the load because the spring is heat-treated after the rolling operation, so that the spring is thus given a predetermined "set or cold worked for accomplishing the same result.

As will become more apparent in connection with the description of Figs. 6 and '7, the end strips 19, I, are amxed to a rigid frame of a seat. and the cell columns form an arcuate or cylindroidal surface which is used for supporting a load. The dimensions of the elliptic cell will be described in connection with Fig. 5.

From the description of the spring given thus far, it follows that a plurality of columns of elliptic cells become either contracted or expanded (depending upon the state of the arc) when they are subjected to load, such contraction being made possible by the existence of the gaps 22 between the columns, the set imparted to the spring, and the arcuate shape of the spring. When a load is imposed on the are formed by a column of elliptic cells, the length of the column contracts with the concomitant contraction of the elliptic cells, each cell acting, in part, in compression, each column responding individually to the imposed load. When the column is deformed by a heavy load to such an extent that its length is made longer than normal. then the cells will begin to expand and act, in part in tension. It should be noted here, however, that the actual stresses in a structure of this type are much more complex than simple compression and tension. Upon the removal of the load, the entire spring returns, because of the imparted set, to its normal, partially spread condition illustrated in Figs. 6 and '7.

Fig. 2 illustrates a modified version of Fig. 1, in which inter-column connections 20 are used between the ends of every fourth pair in longitudinal direction) of adjacent cells. To prevent undesira'ble stiilening of the cells next to the edge strips 2! and 292, the cell rows next to the strips do not have any lateral inter-row connections. Thus, in Fig. 2. two lateral rows of cells, rows 2M and 293 are free of any lateral connections. In the next lateral row 205, cell 206 is connected to cell 291, and cell 208 to cell 209. There are no lateral connections in the next row 2H1. In the succeeding row 212, cell. 2 I3 is connected to cell 2 l4, and 215 to 216; also cell 2H is connected to an adjacent cell in the next column, etc. From then on the lateral, intercolumn connections pattern repeats itself. with no connections in row 220, with the lateral connections in row 222 being identical to those in row 205, no connections in rows 224 and 226, and

row 225 matching row 212. Examination of these connections reveals the fact that they follow diagonal axes 238 through 234 with a free cell interposed between succeeding connections, and the connections next to the edge strips and 282 being omitted. Thus, the cell columns are integrated laterally along the lateral axes: 205, M2, 222, etc., and the cells of each column are interconnected, as in Fig. 1, through interstrand connections along their minor axes to form a plurality of longitudinal columns with the longitudinal column axes 236, 231, etc. The entire assembly represents a single elastic unit which enables one to obtain a more uniform load distribution over the entire spring surface because of the lateral support furnished to any longitudinal column of cells, such as 231, by adjacent column of cells which are to the left (236) and to the right (238) of it. This type of construction gives higher spring efficiency expressed in terms of allowable energy absorption per pound of metal with the concomitant possibility of increasin the natural period of the spring structure. The staggered distribution of the lateral, intercolumn connections enables one toobtain this higher efficiency without perceptibly arresting the elasticity of the individual columns of cells. While Fig. 2 illustrates one type of suitable lateral connections, it is to be understood fiiat other modes of inter-column integration may be used.

It should be borne in mind, however, that it is disadvantageous to interconnect large numbers of cells in adjacent columns because such increase in the degree of latera1 integration precludes lateral extension of the elliptic cells under load. To illustrate, in anextreme case, when all the cells in one column are connected to the adjacent cells in adjacent columns, such over-integra-tion will produce complete paralysis of the entire spring, and would transform the spring into a sheet of well-known "fiat expanded metal, devoid of any springing action, which is useless for the intended purpose.

Fig. 3 discloses a modification of Fig. 2; in Fig. 3 there is a progressive decrease in the strand width of the cells, and a corresponding small increase in the length of the slits. toward the center of the spring. Therefore, the strand width 300 of cell 3532 is larger than a width 304 of a cell 3536, and slit 353? is slig tly shorter than a slit 3%. differently, the strand width decreases progressively from edge strip 3H] toward the center of the spring, and then increases again progressively from the center of the spring toward strip 3! l at the opposite end of the spring. Such strand dimensioning may be used for increasing all rigidities in proportion to anticipated increased stresses nearer the edge strips 3 ii] and 3 i l the anticipated stresses being maximum at the cells adjacent to the edge strips. Therefore, by increasing the strand width of cell 362, adjacent to strip 3 i ii. and thereby slightly decreasing the length oi slit 301, it becomes possible to provide an additional amount of metal to take care of anticipated stress concentrations at the ends of the longitudinal columns.

Fi 3A discloses an additional modification of Fig. 2. Fig. 3A may be considered also as a modification of Fig. 3 in that the strand width de creases progressively from the center of the spring toward the edge strips, and the length of the slits is minimum in the center and maximum next to the edge strips. Thus Fig. 3A represents the reversal of what is disclosed in Fig. 3. This con- I figuration can be used for controlling the shape of the curvature of the spring upon its final stretching across a frame.

Fig. 4 illustrates a modification of Fig. 3; in Fig. 4, the strand width 490 is the same for all cells, but there is an increase in the length of the slits, the slit length 482 of a cell 494, some distance from the edge strip 410, being longer than the slit length 406 of a cell 468, adjacent said strip 450. In this modification the lengths of the slits are least in the cells adjacent to the edge strips M0 and 4| I, and is greatest at the center of the spring. The reasons for this modification are the same as those described in connection with Fig. 3.

From the description of Figs. 1 through 4, it follows that the elasticity and load-carrying capacity of an individual cell may be varied by varying its lateral overall length L, Fig. 5, the length s of the slit and the cross-sectional area of the two semi-elliptic springs or strands 508 and em, constituting the unit cell. This crosssectional area is determined by the strand width W and the strand thickness T. It should be also mentioned that normally the length S of the slit determines the length J of the interstrand connections which join the cells if the lengths of all the slits, S, are made equal to each other. However, the interstrand connection can be controlled independently by decreasing the lengths of those slits which separate the strands from each other, i. e., strand 51!? from strand 524, and strand 593 from strand 522. It is apparent from an examination of Fig. 5 that, with all other d mensions remaining constant, the larger the dimension L is the more elastic the spring is, and the lon er its natural period is. The same is true of the length S of the slit. Similarly, when the dimensions W and T are made smaller the sprin will respond more readily to the loads imnosed u on it. The same is true when, with thickness T remaining constant, width W is decreased to the dimensions capable of resisting twisting of thickness T into the plane of the drawing, i. e., by degrees. The maximum T to W ratio may be of the order in excess of 2 to 1. The ultimate performance of the spring is determined by balancing and selecting all of the above mentioned dimensions to obtain the optimum performance of the entire structure at a given load. Since any of these dimensions can be varied at will in the disclosed structure, a designer is given great freedom to select the optimum dimensions, which produce a spring structure having higher efiiciency. lighter weight and longer period than those obtainable with the known fiat springs. Moreover, introducing a moderate degree of lateral integration between the cell columns by means of the integrating connections produces a single elastic structure having lon itudinal and lateral elasticities, the lateral connections increasin the period of the spring still further because of the possibility of spreading the load over the entire structure.

The figures described thus far, therefore, disclose a single piece metal spring composed of a column of interconnected elliptic cells l2, Fig. 1. symmetrically disposed along a longitudinal axis. such as H5 or IE of the column. Each elliptic cell is composed of two semi-elliptic strands, such as strands 538 and 5H! in Fig. 5, and bonds 5", 555, 5!.8 and 520. The columns of the elliptic cells can be individual columns (by eliminating the edge strips |E!--l or a plurality of laterally spaced columns, the spacing between the columns being illustrated'at 22 in Fig. 1, with the opposite ends of the columns being connected to the edge strips and H, Fig. 1. In the latter case the edge strips and the columns comprise a unitary structure, functioning as a single unit. Fig. 2 also discloses lateral connections between adjacent columns, these connections being uncut bonds 2%. In all cases the spring is imparted an arcuate shape and a permanent set through the heat treating process or cold working.

Figs. 6 and '7 disclose one specific application of the spring to a seat structure, in this particular case to a seat cushion. A G-shaped channel is bent into a rectangular base frame I806. This frame, and rods I86! and I802 spot welded to frame i860 act as a support for two rows of any elastic elements which are illustrated here as coil springs I803 and 1884. These coil springs are attached to the base frame and the rods in well-known. manner.

An elliptic cell spring i885 with the edge strips IBG-a and :80? is mounted on top of the coil springs, whereupon the coil springs are hooked to the edge strips by means of wire clips or spot welded. to them. The structure is stabilized, if so desired, by one or two stabilizing rods such as lEflB, one end of which is connected to frame 1800 and the other end to the edge strip I801. Since the elliptic spring columns, which represent the supporting surface of the seat cushion, were previously arched by means of th shaping belts, into the arcuate shapes, the chord subtending this shape is many times shorter than the chord l8i5 illustrated in Fig. 7. This being the case the spring, because of the permanent set imparted to it during the heat-treating process, will be continuously under stress, this stress tending to restore the spring back to its original arcuate shape, i. e., the spring will try to curl up again. This curling up is resisted by two side rods, only one of which rod IBM is visible in the figure. Rod [8H is connected to, or spot welded to the outer ends of the edge strips I886 and I861, respectively. Thus the edge strips and the rods form a rectangular frame which, together with the coil springs, support the entire elliptic cell spring. This frame can be stifferend considerably by imparting an L-shape to the edge strips prior to passing the sprin sections through the shaping belts, but fter the shearing off operation. A padding I369 and an upholstering material I810 complete the seat cushion.

While there have been described what at present are considered preferred embodiments of the invention, it will be obviou to those skilled in the art that various changes and modifications may be made therein without departing from the invention, and it is therefore aimed in the appended claims to cover all such changes and modifications as fall within the true spirit and scope of the invention.

I claim:

1. A spring including a plurality of laterally spaced columns of interconnected elliptic-cells, two edge strips, 2. connection between one end of each column and one edge strip, and a connection between the opposite end of each column and the other edge strip, said cells, edge strips and connections comprising a unitary metallic structure.

2. An article of manufacture as defined in claim 1 in which none of the cells in adjacent columns are connected to each other.

3. An article of manufacture as defined in claim 8 ,1 in which a limited number of the cells in ad- J'acent columns are interconnected.

4. An article of manufacture as defined in claim 1 in which the widths of the cells as measured along their minor axes increase near the middles of the columns, a limited number of the cells in adjacent columns having means to interconnect their adjacent ends.

5. A seat cushion comprising a base frame, a plurality of elastic element supported by said frame, a spring including front and rear edge strips and a plurality of laterally spaced columns of interconnected elliptic cells between said edge strips, first and second side rods connected between said front and rear strips; said first rod being connected between the left ends of said front and rear edge strips, and said second rod being connected between the right ends of said front and rear edge strips, and connections between said spring and said elastic elements, said elastic elements supporting said spring.

6. A metallic spring comprising a plurality of columns including elliptic cells symmetrically disposed along the longitudinal aXis of the column, each cell having two strands shaped into two, complementary, semi-elliptic springs with a first set of metallic bonds between the outer matching ends of said strands, and a second set of metallic bonds, between mid-portions of adjacent strands, said second set of bonds being disposed along said longitudinal axis, each said column comprising an arcuate, metallically unitary spring, and said strands having arcuate surfaces on the convex side of said arcuate spring; said columns being laterally equally spaced from each other and having substantially equal lengths, a first metallic edge strip interconnecting one end of all of said columns, said edge strip being connected to the mid-portion of the last, outer strand at said one end of each of said columns, and an identical type of edge strip at the opposite ends of said columns, the longitudinal axes of said strips being substantially perpendicular to the longitudinal axes of said columns, said columns and said edge strip comprising a unitary metallic structure.

7. A spring comprising a plurality of semielliptic strands of equal length, the two ends of one strand being metallically bonded to the two ends of adjacent strand, whereby each two complementary strands form an elliptic cell having two strands and two bonded but otherwise free cell-ends. all of the elliptic cell bein symmetrically positioned along a longitudinal axis of said spring to form a column of elliptic cells tenninating at said cell-ends, and metallic bonds between the mid-portions of adjacent strands for integrating said cells into a single metallic spring composed of elliptic spring-cells having free cellends whereby each cell is free to expand and contract in the directions transverse with respect to said longitudinal axis.

8. An article of manufacture comprising elliptic cells of spring material placed together so they have a common minor axis and each cell being connected to adjacent cells along said common minor axis to form a column, at least some of the cells being free at both ends of their major axes whereby they are free to deflect along those axes.

9. An article of manufacture as defined in claim 8 in which the column is arcuate.

19. An article of manufacture as defined in claim 9 in which all the cells are free at both ends of their major axes.

11. An article of manufacture as defined in claim 8 includin at least two of said columns arranged parallel to each other and the majority of complementary cells in adjacent columns being spaced from each other.

12. An articl of manufacture as defined in claim 11 in which said columns are interconnected at complementary ends thereof and in which the whole article is arcuate.

13. An article of manufacture as defined in claim 8 in which the widths of the cells as measured along their minor axis increase near the middle of the column.

14. An article of manufacture as defined in claim 8 in which the widths of the strands of the cells decrease near the middle of the column.

15. An article of manufacture comprising e1- liptic cells of spring material connected to each other along their minor axes to form a column, substantially every cell being free at at least one end of its major axis, whereby substantially all of the cells are free to deflect along their major axes.

16. An article of manufacture as defined in claim 15 in which the elliptic cells are composed of strands having a thickness T and a width W, the order of the dimensional limits of T in terms of W being T=W as a minimum and T=3W as a maximum.

17. An articles of manufacture comprising parallel columns, each column including the following: elliptic cells of spring material connected to each other along their minor axes to form a column, a majority of the cells being free at at least one end of its major axis whereby those cells are free to deflect along their respective major axes.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 176,486 Schnable Apr. 25, 1876 564,531 OBrien July 21, 189 612,620 Van Devanter Oct. 18, 1898 1,451,936 Young Apr. 17, 192 1,845,980 Kessler Feb. 16, 1932 1,850,543 Gersman Mar. 22, 1932 1,862,221 Kaminetsky June 7, 1932 1,881,997 Browne Oct. 11, 1932 2,104,249 Vass Jan. 4, 1938 2,242,540 Nordmark May 20, 1941 2,257,367 Bernstein Sept. 30, 1941 2,280,840 Neely Apr. 28, 1942 2,302,479 Tallmadge Nov. 17, 1942 2,306,150 Asaro Dec. 22, 1942 2,400,426 Liptay et al May 14, 1946 

